U.S. patent number 6,592,067 [Application Number 09/780,733] was granted by the patent office on 2003-07-15 for minimizing paper waste carousel-style dispenser apparatus, sensor, method and system with proximity sensor.
This patent grant is currently assigned to Georgia-Pacific Corporation. Invention is credited to Joshua Michael Broehl, Dennis Joseph Denen, Robert James Hayes, John Joseph Knittle, Brian Kenneth Linstedt, Gregory James Merz, John R. Moody, Craig D. Yardley.
United States Patent |
6,592,067 |
Denen , et al. |
July 15, 2003 |
Minimizing paper waste carousel-style dispenser apparatus, sensor,
method and system with proximity sensor
Abstract
Apparatus for dispensing paper from rolls which feeds
continuously, roll to roll, and does not require extra procedure to
bring stub roll into position. The apparatus has a device for
holding and positioning at least first and second rolls of paper
with respect to each other; a device for dispensing paper from the
first roll; a device for dispensing paper from the first and second
rolls simultaneously when the first roll reduces to a predetermined
diameter of paper, a device for positioning the depleted first roll
for replacement without the necessity of removing the second roll;
and a device for dispensing from the second and replacement rolls
simultaneously when the second roll reduces to a predetermined
diameter of paper. The apparatus also has a capacity-change based
proximity sensor comprising a circuit according to a balanced
bridge principle where detection is based on detecting a phase
difference, which depends upon the amount of detected capacitance
difference or change. The proximity detector senses when a hand is
placed near the dispenser, and thereupon dispenses a set amount of
towel. It does not keep dispensing the towel. The hand must be
withdrawn and placed in proximity to the sensor again.
Inventors: |
Denen; Dennis Joseph
(Westerville, OH), Yardley; Craig D. (Deer Park, IL),
Broehl; Joshua Michael (Worthington, OH), Hayes; Robert
James (Lewis Center, OH), Knittle; John Joseph
(Westerville, OH), Linstedt; Brian Kenneth (Ostrander,
OH), Merz; Gregory James (Gahanna, OH), Moody; John
R. (Neenah, WI) |
Assignee: |
Georgia-Pacific Corporation
(Atlanta, GA)
|
Family
ID: |
25120505 |
Appl.
No.: |
09/780,733 |
Filed: |
February 9, 2001 |
Current U.S.
Class: |
242/560;
242/560.1 |
Current CPC
Class: |
A47K
10/3687 (20130101); H03K 17/955 (20130101); H05F
3/02 (20130101); A47K 10/38 (20130101); B65H
20/005 (20130101); B65H 19/126 (20130101); A47K
10/3643 (20130101); A47K 10/34 (20130101); A47K
2010/3253 (20130101); A47K 2010/326 (20130101); Y10S
242/906 (20130101); A47K 2010/3233 (20130101); A47K
2010/3668 (20130101) |
Current International
Class: |
A47K
10/24 (20060101); A47K 10/36 (20060101); H05F
3/02 (20060101); B65H 019/00 () |
Field of
Search: |
;242/560,560.1,560.3,564.4 ;312/34.22 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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3342921 |
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Jun 1985 |
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DE |
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0 459 050 |
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Dec 1991 |
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EP |
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2539293 |
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Jul 1984 |
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FR |
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2583729 |
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Dec 1986 |
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FR |
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2771620 |
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Jun 1999 |
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FR |
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2058014 |
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Apr 1981 |
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GB |
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2267271 |
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Dec 1993 |
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GB |
|
Primary Examiner: Nguyen; John Q.
Attorney, Agent or Firm: Fulbright & Jaworski L.L.P.
Claims
What is claimed is:
1. A paper towel dispenser, comprising: a carousel assembly adapted
to support a first paper roll over a second paper roll in a first
position and to rotate about a first axis defined between said
first and second paper rolls wherein each of said first and second
paper rolls has a core; means for locking said rotating carousel
assembly in said first position for paper towel dispensing and in a
second position for paper roll loading, said carousel assembly
adapted to support a newly loaded second roll over said first roll
in said second position; and means for sequentially dispensing
paper towels from said first and second paper rolls, comprising:
(a) at least one paper towel feed mechanism disposed downstream
from said carousel assembly; and (b) at least one paper roll
transfer mechanism disposed between said at least one paper towel
feed mechanism and said carousel assembly, said at least one paper
roll transfer mechanism being adapted to contact said second paper
roll when said carousel assembly is locked in said first position
for dispensing paper towels from said second paper roll in
conjunction with said at least one paper towel feed mechanism until
said second paper roll is nearly exhausted, and for dispensing
paper towels from said first and second paper rolls in conjunction
with said at least one paper towel feed mechanism until said second
paper roll is completely exhausted, said at least one paper roll
transfer mechanism being adapted to contact the core of said
completely exhausted second paper roll when said carousel assembly
is locked in said first position for dispensing paper towels from
said first paper roll in conjunction with said at least one paper
towel feed mechanism until said first paper roll is reduced to a
pre-determined diameter, said at least one paper roll transfer
mechanism being adapted to contact said reduced first paper roll
when said carousel assembly is rotated and locked in said second
position for loading a new second roll and for dispensing paper
towels from said reduced first paper roll in conjunction with said
at least one paper towel feed mechanism until said reduced first
paper roll is nearly exhausted, and from said first and newly
loaded second paper rolls in conjunction with said at least one
paper towel feed mechanism until said first paper roll is
completely exhausted.
2. The paper towel dispenser of claim 1, wherein said at least one
paper towel feed mechanism includes at least one feed roller
operatively coupled to a nib roller, said at least one feed roller
being driven by a motor means.
3. The paper towel dispenser of claim 1, wherein said at least one
paper roll transfer mechanism includes at least one generally
U-shaped and spring-loaded paper roll transfer bar.
4. The paper towel dispenser of claim 3, further comprising a
housing.
5. The paper towel dispenser of claim 4, wherein said carousel
assembly comprises a pair of oppositely disposed paper roll support
arms coupled respectively to a pair of support bars, each of said
support bars being rotatably coupled to said housing by way of a
carousel rotation hub, said carousel rotation hubs defining said
first axis.
6. The paper towel dispenser of claim 5, further comprising a pair
of cross members coupled respectively to said pair of rotatable
support bars, each of said cross members being adapted to serve as
a stiffener for said carousel assembly.
7. The paper towel dispenser of claim 6, wherein each of said cross
members is adapted to serve as a paper guide for said carousel
assembly.
8. The paper towel dispenser of claim 5, wherein said locking means
includes at least one locking bar adapted to slidably ride on one
of said support bars.
9. The paper towel dispenser of claim 8, wherein said at least one
locking bar is spring-loaded to resist the unwarranted release of
said locked carousel assembly, said locked carousel assembly being
unlocked by pulling said at least one spring-loaded locking bar
away from said housing.
10. The paper towel dispenser of claim 9, wherein said locked
carousel assembly is biased to rotate toward said transfer bar when
unlocked.
11. The paper towel dispenser of claim 5, wherein each of said
paper roll support arms includes a pair of oppositely disposed
paper roll hubs adapted to removably engage each of said first and
second paper rolls.
12. A method for dispensing paper towels, comprising the steps of:
(a) providing a carousel assembly adapted to support a first paper
roll over a second paper roll in a first position and to rotate
about a first axis defined between said first and second paper
rolls wherein each of said first and second paper rolls has a core;
(b) locking said rotating carousel assembly in said first position
for paper towel dispensing; (c) utilizing a paper roll transfer
mechanism to contact said second paper roll when said carousel
assembly is locked in said first position for dispensing paper
towels from said second paper roll in conjunction with a paper
towel feed mechanism disposed downstream from said carousel
assembly until said second paper roll is nearly exhausted, and for
dispensing paper towels from said first and second paper rolls in
conjunction with said paper towel feed mechanism until said second
paper roll is completely exhausted; (d) utilizing said paper roll
transfer mechanism to contact the core of said completely exhausted
second paper roll when said carousel assembly is locked in said
first position for dispensing paper towels from said first paper
roll in conjunction with said paper towel feed mechanism until said
first paper roll is reduced to a pre-determined diameter; (e)
unlocking said carousel assembly from said first position; (f)
rotating said unlocked carousel assembly to a second position, said
carousel assembly adapted to support a newly loaded second paper
roll over said first paper roll in said second position; (g)
locking said carousel assembly in said second position for loading
a new second roll; and (h) utilizing said paper roll transfer
mechanism to contact said reduced first paper roll when said
carousel assembly is locked in said second position for dispensing
paper towels from said reduced first paper roll in conjunction with
said paper towel feed mechanism until said reduced first paper roll
is nearly exhausted, and from said first and newly loaded second
paper rolls in conjunction with said paper towel feed mechanism
until said first paper roll is completely exhausted.
13. A paper roll dispenser, comprising: means for holding a first
paper roll; means for holding a second paper roll; means for
supporting said first paper roll holding means and said second
paper roll holding means, said supporting means being adapted to
rotate about an axis defined between said first and second paper
roll holding means; means for sequentially dispensing paper towels
from said first and second paper rolls disposed downstream from
said rotatble supporting means; and a proximity detector adapted to
trigger the dispensing of paper when a user's hand is positioned
within the field of said detector, said proximity detector
comprising: a first comparator configured as an oscillator; a
capacitive proximity sensor (CPS) operatively coupled to said
oscillator; a reference capacitor (Cref) operatively coupled
between said oscillator and circuit ground and adapted to
approximate the capacitance of said CPS; a variable trim resistor
(Rtrim) connected in series between said CPS and said Cref; a
second comparator adapted to receive analog input signals from said
CPS and said Cref and generate a digital output signal; and a D
flip-flop adapted to latch and hold said digital output signal from
said second comparator.
14. The paper roll dispenser of claim 13, further comprising a
control module operatively coupled to a motor means for dispensing
paper from at least one paper roll, said control module including a
first switch adapted to control the length of paper being dispensed
by said motor means.
15. The paper roll dispenser of claim 14 wherein said control
module further includes a second switch adapted to set a time delay
between successive paper dispensations by said motor means.
16. The paper roll dispenser of claim 15 wherein said control
module further includes a third switch adapted to vary the
resistance value of Rtrim for adjusting the sensitivity of said
proximity detector.
17. The paper roll dispenser of claim 13, further comprising means
for visually guiding a user's hand toward said proximity detector,
said means including a pseudo-button disposed within a sunrise-like
setback on a cover for said paper roll dispenser near said
proximity detector.
18. A method for dispensing paper towels, comprising the steps of:
(a) providing a carousel assembly adapted to support a first paper
roll over a second paper roll and to rotate about a first axis
defined between said first and second paper rolls, each of said
first and second paper rolls having a core; (b) providing motor
means for dispensing paper towels from at least one of said first
and second paper rolls on said carousel assembly; (c) providing a
proximity detector adapted to trigger the dispensing of paper
towels by said motor means when a user's hand is positioned within
the field of said detector; (d) locking said rotating carousel
assembly in a first position for paper towel dispensing; (e)
utilizing a generally U-shaped spring-loaded transfer bar to
contact said second paper roll when said carousel assembly is
locked in said first position for dispensing paper towels from said
second paper roll in conjunction with a paper towel feed mechanism
disposed downstream from said carousel assembly until said second
paper roll is nearly exhausted and from said first and second paper
rolls in conjunction with said paper towel feed mechanism until
said second paper roll is completely exhausted; (f) utilizing said
transfer bar to contact the core of said completely exhausted
second paper roll for dispensing paper towels from said first paper
roll in conjunction with said paper towel feed mechanism until said
first paper roll is reduced to a pre-determined diameter; (g)
unlocking said carousel assembly from said first position; (h)
rotating said unlocked carousel assembly to a second position
approximately 180 degrees apart from said first position; (i)
locking said carousel assembly in said second position for loading
a new second roll; and (j) utilizing said transfer bar to contact
said reduced first paper roll when said carousel assembly is locked
in said second position for dispensing paper towels from said
reduced first paper roll in conjunction with said paper towel feed
mechanism until said first paper roll is nearly exhausted and from
said first and newly loaded second paper rolls in conjunction with
said paper towel feed mechanism until said first paper roll is
completely exhausted.
19. The method of claim 18, wherein step (c) comprises the
following sub-steps: (c1) configuring a first comparator as an
oscillator; (c2) operatively coupling a capacitive proximity sensor
(CPS) and a reference capacitor (Cref) to said oscillator according
to a bridge balance principle; (c3) connecting a variable trim
resistor (Rtrim) in series between said CPS and said Cref; (c4)
providing a second comparator adapted to receive analog input
signals from said CPS and said Cref and generate a digital output
signal; (c5) providing a D flip-flop adapted to latch and hold said
digital output signal from said second comparator, said D flip-flop
having an output state; and (c6) activating a motor switch upon
detecting a change in the output state of said D flip-flop.
Description
FIELD OF THE INVENTION
This invention relates to the field of paper roll dispensers. In
particular it relates to a carousel dispensing system for paper
towels adapted to dispense paper from a plurality of rolls. This
invention relates to the field of proximity sensors. In particular
it relates to the field of phase-balance proximity sensors.
BACKGROUND
As is readily apparent, a long-standing problem is to keep paper
towel available in a dispenser and at the same time use up each
roll as completely as possible to avoid paper waste. As part of
this system, one ought to keep in mind the person who refills the
towel dispenser. An optimal solution would make it as easy as
possible and as "fool-proof" as possible to operate the towel
refill system and have it operate in such a manner as the least
amount of waste of paper towel occurs. This waste may take the form
of "stub" rolls of paper towel not being used up.
Transfer devices are used on some roll towel dispensers as a means
of reducing waste and decreasing operating costs. These transfer
devices work in a variety of ways. The more efficient of these
devices automatically begin feeding from a reserve roll once the
initial roll is exhausted. These devices eliminate the waste caused
by a maintenance person when replacing small rolls with fresh rolls
in an effort to prevent the dispenser from running out of paper.
These transfer devices, however, tend to be difficult to load
and/or to operate. Consequently, these transfer devices are less
frequently used, even though they are present.
The current transfer bar mechanisms tend to require the maintenance
person to remove any unwanted core tube(s), remove the initial
partial roll from the reserve position, and position the initial
partial roll into the now vacant stub roll position. This procedure
is relatively long and difficult, partly because the stub roll
positions in these current paper towel dispensers tend to be
cramped and difficult to get to.
In order to keep a roll available in the dispenser, it is necessary
to provide for a refill before the roll is used up. This factor
generally requires that a "refill" be done before the current paper
towel roll is used up. If the person refilling the dispenser comes
too late, the paper towel roll will be used up. If the refill
occurs too soon, the amount of paper towel in the almost used-up
roll, the "stub" roll, will be wasted unless there is a method and
a mechanism for using up the stub roll even though the dispenser
has been refilled. Another issue exists, as to the ease in which
the new refill roll is added to the paper towel dispenser. The goal
is to bring "on-stream" the new refill roll as the last of the stub
roll towel is being used up. If it is a task easily done by the
person replenishing the dispensers, then a higher probability
exists that the stub roll paper towel will actually be used up and
also that a refill roll be placed into service before the stub roll
has entirely been used up. It would be extremely desirable to have
a paper towel dispenser which tended to minimize paper wastage by
operating in a nearly "fool proof" manner with respect to refilling
and using up the stub roll.
As an enhancement and further development of a system for
delivering paper towel to the end user in as cost effective manner
and in a user-friendly manner as possible, an automatic means for
dispensing the paper towel is desirable, making it unnecessary for
a user to physically touch a knob or a lever.
It has long been known that the insertion of an object with a
dielectric constant into a volume with an electrostatic field will
tend to modify the properties which the electrostatic field sees.
For example, sometimes it is noticed that placing one hand near
some radios will change the tuning of that radio. In these cases,
the property of the hand, a dielectric constant close to that of
water, is enough to alter the net capacitance of a tuned circuit
within the radio, where that circuit affects the tuning of the RF
signal being demodulated by that radio. In 1973 Riechmann (U.S.
Pat. No. 3,743,865) described a circuit which used two antenna
structures to detect an intrusion in the effective space of the
antennae. Frequency and amplitude of a relaxation oscillator were
affected by affecting the value of its timing capacitor.
The capacity (C) is defined as the charge (Q) stored on separated
conductors with a voltage (V) difference between the
conductors:
For two infinite conductive planes with a charge per unit area of
.sigma., a separation of d, with a dielectric constant .di-elect
cons. of the material between the infinite conductors, the
capacitance of an area A is given by:
Thus, where part of the separating material has a dielectric
constant .di-elect cons..sub.1 and part of the material has the
dielectric constant .di-elect cons..sub.2, the net capacity is:
The human body is about 70% water. The dielectric constant of water
is 7.18.times.10.sup.-10 farads/meter compared to the dielectric
constant of air (STP): 8.85.times.10.sup.-12 farads/meter. The
dielectric constant of water is over 80 times the dielectric
constant of air. For a hand thrust into one part of space between
the capacitor plates, occupying, for example, a hundredth of a
detection region between large, but finite parallel conducting
plates, a desirable detection ability in terms of the change in
capacity is about 10.sup.-4. About 10.sup.-2 is contributed by the
difference in the dielectric constants and about 10.sup.-2 is
contributed by the "area" difference.
Besides Riechmann (1973), other circuits have been used for, or
could be used for proximity sensing.
An important aspect of a proximity detector circuit of this type is
that it be inexpensive, reliable, and easy to manufacture. A
circuit made of a few parts tends to help with reliability, cost
and ease of manufacture. Another desirable characteristic for
electronic circuits of this type is that they have a high degree of
noise immunity, i.e., that they work well where there may be
electromagnetic noise and interference. The circuit will perform
better in more locations. It will have acceptable performance in
more areas of application.
SUMMARY OF THE INVENTION
The invention comprises to a carousel-based dispensing system for
paper towels, in particular, which acts to minimize actual wastage
of paper towels. The invention comprises means for holding and
positioning at least first and second rolls of paper with respect
to each other, means for dispensing paper from the first roll,
means for dispensing paper from the first and second rolls
simultaneously when the first roll reduces to a predetermined
diameter of paper, means for positioning the depleted first roll
for replacement without the necessity of removing the second roll
and means for dispensing from the second and replacement rolls
simultaneously when the second roll reduces to a predetermined
diameter of paper.
The proximity sensor embodiment comprises a circuit according to a
balanced bridge principle where detection is based on detecting a
phase difference, which depends upon the amount of detected
capacitance difference or change of capacitance in a region of
detection.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, and the
advantages thereof, reference is now made to the following
descriptions taken in conjunction with the accompanying drawings,
in which:
FIG. 1 is a side elevation of the dispenser with the cover closed,
with no internal mechanisms visible;
FIG. 2 is a perspective view of the dispenser with the cover
closed, with no internal mechanisms visible;
FIG. 3 shows a view of the carousel support, the locking bar and
the transfer bar;
FIG. 4A is a perspective view of the of the dispenser with the
carousel and transfer bar, fully loaded with a main roll and a stub
roll;
FIG. 4B is a side view of the locking bar showing the placement of
the compression springs;
FIG. 4C shows the locking mechanism where the locking bar closest
to the rear of the casing is adapted to fit into a mating structure
in the rear casing;
FIG. 5 is a perspective, exploded view of the carousel
assembly;
FIG. 6A is a side elevation view of the paper feeding from the stub
roll while the tail of the main roll is positioned beneath the
transfer bar;
FIG. 6B is a side elevation view of the stub roll is completely
exhausted, so that the transfer bar tucks the tail of the main roll
into the feed mechanism;
FIG. 7A is a side elevation view of the carousel ready for loading
when the main roll reaches a specific diameter;
FIG. 7B is a side elevation view of the locking bar being pulled
forwardly to allow the carousel to rotate 180.degree., placing the
main roll in the previous stub roll position;
FIG. 7C shows the extension springs which tend to maintain the
transfer bar legs in contact with the stub roll;
FIG. 7D shows the cleanable floor of the dispenser;
FIG. 8A shows a schematic of the proximity circuit;
FIG. 8B (prior art) shows the schematic for the National
Semiconductor dual comparator LM393;
FIG. 9A shows the square wave output at U1A, pin 1;
FIG. 9B shows the RC exponential waveforms at pins 5; and
FIG. 9C shows the RC exponential waveforms at pin 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The following description is of the best mode presently
contemplated for carrying out the invention. This description is
not to be taken in a limiting sense, but is merely made for the
purpose of describing the general principles of the invention. The
scope of the invention should be determined with reference to the
claims.
An embodiment of the invention comprises a carousel-based
dispensing system with a transfer bar for paper towels, which acts
to minimize actual wastage of paper towels. As an enhancement and
further development of a system for delivering paper towel to the
end user in a cost effective manner and in as user-friendly manner
as possible, an automatic means for dispensing the paper towel is
desirable, making it unnecessary for a user to physically touch a
knob or a lever. An electronic proximity sensor is included as part
of the paper towel dispenser. A person can approach the paper towel
dispenser, extend his or her hand, and have the proximity sensor
detect the presence of the hand. The embodiment of the invention as
shown here, is a system, which advantageously uses a minimal number
of parts for both the mechanical structure and for the electronic
unit. It has, therefore, an enhanced reliability and
maintainability, both of which contribute to cost
effectiveness.
An embodiment of the invention comprises a carousel-based
dispensing system with a transfer bar for paper towels, which acts
to minimize actual wastage of paper towels. The transfer bar
coupled with the carousel system is easy to load by a service
person; consequently it will tend to be used, allowing stub rolls
to be fully utilized. In summary, the carousel assembly-transfer
bar comprises two components, a carousel assembly and a transfer
bar. The carousel rotates a used-up stub roll to an up position
where it can easily be replaced with a full roll. At the same time
the former main roll which has been used up such that its diameter
is less than some p inches, where p is a rational number, is
rotated down into the stub roll position. The tail of the new main
roll in the upper position is tucked under the "bar" part of the
transfer bar. As the stub roll is used up, the transfer bar moves
down under spring loading until the tail of the main roll is
engaged between the feed roller and the nib roller. The carousel
assembly is symmetrical about a horizontal axis. A locking bar is
pulled out to unlock the carousel assembly and allow it to rotate
about its axis, and is then released under its spring loading to
again lock the carousel assembly in place.
A side view, FIG. 1, of the dispenser 20 with the cover 22 in place
shows an upper circular bulge 24, providing room for a full roll of
paper towel, installed in the upper position of the carousel. The
shape of the dispenser is such that the front cover tapers inwardly
towards the bottom to provide a smaller dispenser volume at the
bottom where there is a smaller stub roll of paper towel. The shape
tends to minimize the overall size of the dispenser. FIG. 2 shows a
perspective view of the dispenser 20 with cover 22 in place and the
circular (cylindrical) bulge 24, together with the sunrise-like
setback 26 on the cover 22, which tends to visually guide a hand
toward the pseudo-button 28, leading to activation of a proximity
sensor (not shown). A light emitting diode (LED) 130 is located
centrally to the pseudo-button 28. The LED 130 (FIG. 3) serves as
an indication that the dispenser 20 is on, and dispensing towel.
The LED 130 may be off while the dispenser is not dispensing.
Alternatively, the LED 130 may be lit (on), and when the dispenser
20 is operating, the LED 130 might flash. The LED 130 might show
green when the dispenser 20 is ready to dispense, and flashing
green, or orange, when the dispenser 20 is operating to dispense.
Any similar combination may be used. The least power consumption is
where the LED 130 only lights during a dispensing duty cycle. The
sunrise-like setback 26 (FIG. 2) allows a hand to come more closely
to the proximity sensor (not shown).
FIG. 3 shows the main elements of the carousel assembly 30. The
carousel arms 32 have friction reducing rotating paper towel roll
hubs 34, which are disposed into the holes of a paper towel roll
(66, 68, FIG. 4A). The locking bar 36 serves to lock and to release
the carousel for rotation about its axis 38. The locking bar 36
rides on one of the corresponding bars 40. The two corresponding
bars 40 serve as support bars. Cross-members 42 serve as stiffeners
for the carousel assembly 30 and also serve as paper guides for the
paper to be drawn over and down to the feed roller 50 and out the
dispenser 20. These cross members are attached in a rigid fashion
to the corresponding bars 40 and in this embodiment do not
rotate.
The legs 46 of the transfer bar 44 do not rest against the friction
reducing rotating paper towel roll hubs 34 when there is no stub
roll 68 present but are disposed inward of the roll hubs 34. The
bar part 88 of the transfer bar 44 will rest against a structure of
the dispenser, for example, the top of modular electronics unit
132, when no stub roll 68 is present. The bar part 88 of the
transfer bar 44 acts to bring the tail of a new main roll of paper
towel 66 (FIG. 4A) down to the feed roller 50 which includes
intermediate bosses 146 (FIG. 3) and shaft 144. The carousel
assembly is disposed within the fixed casing 48. The cover is not
shown.
Feed roller 50 serves to feed the paper towels 66, 68 (FIG. 4A)
being dispensed onto the curved dispensing ribs 52. The curved
dispensing ribs 52 are curved and have a low area of contact with
the paper towel dispensed (not shown). If the dispenser 20 gets
wet, the curved dispensing ribs 46 help in dispensing the paper
towel to get dispensed by providing low friction and by holding he
dispensing towel off of the wet surfaces it would otherwise
contact.
The feed roller 50 is typically as wide as the paper roll, and
includes drive rollers 142 and intermediate bosses 146 on the drive
shaft 144. The working drive rollers or drive bosses 142 (FIG. 3)
are typically an inch or less in width, with intermediate bosses
146 (FIG. 3) located between them. Intermediate bosses 146 are
slightly less in diameter than the drive rollers or drive bosses
142, having a diameter 0.015 to 0.045 inches less than the drive
rollers or drive bosses 142. In this embodiment, the diameter of
the intermediate bosses 146 is 0.030 inches less than the drive
roller 142. This configuration of drive rollers or drive bosses 142
and intermediate bosses 146 tends to prevent the dispensing paper
towel from becoming wrinkled as is passes through the drive
mechanism and reduces friction, requiring less power to operate the
feed roller 50.
A control unit 54 operates a motor 56. Batteries 58 supply power to
the motor 56. A motor 56 may be positioned next to the batteries
58. A light 60, for example, a light-emitting diode (LED), may be
incorporated into a low battery warning such that the light 60
turns on when the battery voltage is lower than a predetermined
level.
The cover 22 of the dispenser is preferably transparent so that the
amount of the main roll used (see below) may be inspected, but also
so that the battery low light 60 may easily be seen. Otherwise an
individual window on an opaque cover 22 would need to be provided
to view the low battery light 60. Another approach might be to lead
out the light by way of a fiber optic light pipe to a transparent
window in the cover 22.
In a waterproof version of the dispenser, a thin piece of foam
rubber rope is disposed within a u-shaped groove of the
tongue-in-groove mating surfaces of the cover 22 and the casing 48.
The dispensing shelf 62 is a modular component, which is removable
from the dispenser 20. In the waterproof version of the dispenser
20, the dispensing shelf 62 with the molded turning ribs 52 is
removed. By removing the modular component, dispensing shelf 62,
there is less likelihood of water being diverted into the dispenser
20 by the dispensing shelf 62, acting as a funnel or chute should a
water hose or spray be directed at the dispenser 20, by the shelf
and wetting the paper towel. The paper towel is dispensed straight
downward. A most likely need for a waterproof version of the
dispenser is where a dispenser is located in an area subject to
being cleaned by being hosed down. The dispenser 20 has an on-off
switch which goes to an off state when the cover 22 is pivoted
downwardly. The actual switch is located on the lower face of the
nodule 54 and is not shown.
In one embodiment, the user may actuate the dispensing of a paper
towel by placing a hand in the dispenser's field of sensitivity.
There can be adjustable delay lengths between activations of the
sensor.
There is another aspect of the presence of water on or near the
dispenser 20. A proximity sensor (not visible) is more fully
discussed below, including the details of its operation. However,
as can be appreciated, the sensor detects changes of capacitance
such as are caused by the introduction of an object with a high
dielectric constant relative to air, such as water, as well as a
hand which is about 70% water. An on-off switch 140 is provided
which may be turned off before hosing down and may be turned on
manually, afterwards. The switch 140 may also work such that it
turns itself back on after a period of time, automatically. The
switch 140 may operate in both modes, according to mode(s) chosen
by the user.
A separate "jog" off-on switch 64 is provided so that a maintenance
person can thread the paper towel 66 by holding a spring loaded jog
switch 64 which provides a temporary movement of the feed roller
50.
FIG. 4A shows the dispenser case 48 with the carousel assembly 30
and transfer bar 44. The carousel assembly 30 is fully loaded with
a main roll 66 and a stub roll 68, both mounted on the carousel
arms 32 and rotate on the rotating reduced friction paper towel
roll hubs 34 (only shown from the back of the carousel arms 32). In
the carousel assembly 30, the two carousel arms 32, joined by
corresponding bars 40 and cross members 42, rotate in carousel
fashion about a horizontal axis defined by the carousel assembly
rotation hubs 38. The locking bar 36 is supported, or carried, by a
corresponding bar 40. The corresponding bar 40 provides structural
rigidity and support. The locking bar 36 principally serves as a
locking mechanism. Each paper towel roll 66, 68 has an inner
cardboard tube which acts as a central winding core element, and
which provides in a hole in paper towel roll 66, 68 at each end for
engaging the hubs 34.
FIG. 5 shows the carousel assembly 30 in exploded, perspective
view. The number of parts comprising this assembly is small. From a
reliability point of view, the reliability is increased. From a
manufacturing point of view, the ease of manufacture is thereby
increased and the cost of manufacture is reduced. The material of
manufacture is not limited except as to the requirements of cost,
ease of manufacture, reliability, strength and other requirements
imposed by the maker, demand.
When the main roll, 66 (FIG. 4A) and the stub roll 68, (FIG. 4A)
are in place, the carousel arms 32 are connected by these rolls 66
and 68 (FIG. 4A). Placing cross-members 42 to connect the carousel
arms 32 with the locking 36 and corresponding 40 bar results in
better structural stability, with racking prevented. The locking
bar 36, which was shown as a single unit locking bar 36 in the
previous figures, acts as a locking bar 36 to lock the carousel
assembly 30 in the proper orientation. It acts also as the release
bar, which when released, allows the carousel assembly 30 to
rotate. Two compression springs 70, 72 are utilized to center the
locking bar 36.
FIG. 4B is a side view of the locking bar showing the placement of
the compression springs. The compression springs 70, 72 also tend
to resist the release of the locking bar 36, insuring that a
required force is needed to unlock the locking bar 36. The required
force is typically between 0.5 lbf and 3.0 lbf, or more. In this
embodiment, the force is 2.0 lbf when the spring in a fully
compressed position, and 1.1 lbf when the spring is in the rest
position. In the rest position, the forces of the opposing springs
offset each other.
The actual locking occurs as shown in FIG. 4C. The locking bar 36
closest to the rear of the casing 48 is adapted to fit into a
generally unshaped mating structure 118 which is adapted to hold
the locking bar 36 and prevent it and the carousel assembly 30 from
rotating. When the locking bar 36 is pulled away from the rear of
the casing 48, the locking bar 36 is disengaged from the mating
structure 118. The mating structure has an upper "high" side 120
and a lower "low" side 122, where the low side has a "ramp" 124 on
its lower side. As the locking bar 36 is pulled out to clear the
high side 120, the carousel assembly 30 is free to rotate such that
the top of the carousel assembly 30 rotates up and away from the
back of the casing 48. As the carousel assembly 30 begins to
rotate, the user releases the locking bar 36 which, under the
influence of symmetrically placed compression springs 70, 72
returns to its rest position. As he carousel assembly rotates, the
end of the symmetrical locking bar 36 which originally was disposed
toward the user now rotates and contacts the ramp 124. A locking
bar spring, e.g., 70 or 72, is compressed as the end of the locking
bar 36 contacting the ramp 124 now moves up the ramp 124. The end
of the locking bar 36 is pressed into the space between the low
side 122 and the high side 120, as the end of the locking bar 36
slides past the low side 122. A locked position for the carousel
assembly 30 is now reestablished.
FIG. 5 shows the carousel arms 32 adapted to receive the loading of
a new roll of towel 66 (FIG. 4A). The arms 32 are slightly flexible
and bent outward a small amount when inserting a paper towel roll
66 (FIG. 4A) between two opposite carousel arms 32. A friction
reducing rotating paper towel roll hub 34 is inserted into a hole
of a paper towel roll 66 (FIG. 4A), such that one roll hub 34 is
inserted into a hole on each side of the paper towel roll 66 (FIG.
4A). Also shown in FIG. 5 are the tamper resistant fasteners 74,
which attach the friction-reducing rotating paper towel roll hubs
34 to the carousel arms 32.
FIG. 5 shows the surface 76 of the roll hubs 34 and the surface 78
of the carousel arms 66, which contact each other. These contact
surfaces 76, 78 may be made of a more frictionless material than
that of which the carousel arms 32 and the roll hubs 34 are made.
For example, a plastic such as polytetrafluoroethylene (PTFE),
e.g., TEFLON.RTM., may be used, as a thin layer on each of the
contacting surfaces. The paper towel dispenser 20 and its
components may be made of, including but not limited to, plastic,
metal, an organic material which may include but is not limited to
wood, cardboard, treated or untreated, a combination of these
materials, and other materials for batteries, paint, if any, and
waterproofing.
FIG. 6A shows the paper 80 feeding from the stub roll 68 while the
tail 82 of the main roll 66 is positioned beneath the transfer bar
44. The legs (visible leg 46, other leg not shown) of the transfer
bar 44 rests against the stub roll. When the diameter of the stub
roll 68 is larger by a number of winds of paper towel than the
inner roll 84, the legs 46 of the transfer bar 44 dispose the bar
88 of the transfer bar 44 to be rotated upward from the feed roller
50.
FIG. 6B shows the situation where the stub roll 68 is exhausted, so
that the transfer bar 44 tucks the tail 82 of the main roll 66 into
the feed mechanism 86. FIG. 6B shows the stub roll 68 position
empty, as the stub roll has been used up. The stub roll core 84 is
still in place. As the stub roll 68 is used up, the legs 46 of the
transfer bar 44 move up toward the stub roll core (inner roll) 84,
and the bar 88 of the transfer bar is disposed downward toward the
feed roller 50 and toward the top of a structural unit of the
dispenser 20 (FIG. 2), such as the top of the electronics module
132 (FIG. 3). Initially the main roll 66 is in reserve, and its
tail 82 in an "idling" position such that it is under the transfer
bar 44. The main roll 66 and its tail 82 are not initially in a
"drive" position. However, as the stub roll 68 is used up, the
downward motion of the bar transfer bar, 44 driven by its spring
loading, brings the bar 88 of the transfer bar 44 down to engage
the main roll tail 82 with the feed roller 50.
FIG. 7A shows the carousel assembly 30 ready for loading when the
main roll 66 reaches a specific diameter. The diameter of the main
roll 66 may be measured by comparison of that diameter with the
widened "ear" shape 122 (FIG. 4A) on each end of the carousel arms
32. That part of each carousel arm 32 is made to measure a critical
diameter of a main roll 66. The carousel assembly 30 is tilted
forward when it is locked. The carousel assembly 30 may rotate
unassisted after the locking bar 36 is released, due to the
top-heavy nature of the top roll. That is, the torque produced by
the gravitational pull on the main-roll 66 is larger than that
needed to overcome friction and the counter-torque produced by the
now empty stub roll 68.
FIG. 7B shows the process of loading where the service person pulls
the locking bar 36 and allows the carousel to rotate 180.degree.,
placing the main roll 66 in the previous stub roll 68 position. Now
a new full sized roll 66 can be loaded onto the main roll 66
position. The transfer bar 44 automatically resets itself. The
transfer bar 44 is spring loaded so as to be disposed with the
transfer bar legs 46 pressed upward against the stub roll 68 or the
stub roll core 84. The transfer bar legs 46 are adapted to be
disposed inward of the roll hubs 34 so the bar 88 of the transfer
bar 44 will have a positive stop at a more rigid location, in this
case, the top of the electronics module 132 (FIG. 2).
FIG. 7C shows the extension springs 126, 128 which tend to maintain
the transfer bar legs 46 in contact with the stub roll 68 or stub
roll core 84. The transfer bar 44 contains the two extension
springs 126, 128. The spring forces are typically 0.05 lbf to 0.5
lbf in the bar 44 lowered position and 0.2 lbf to 1.0 lbf in the
bar 44 raised position. In this embodiment, the spring forces are
0.2 lbf in the lowered position an 0.43 lbf in the raised position.
The force of the two springs 126, 128 is additive so that the
transfer bar 44 is subject to a total spring force of 0.4 lbf in
the lowered position and 0.86 lbf in the raised position.
While modular units (FIG. 7D) such as the electronics module 132,
the motor 56 module, and the battery case 150, are removable, they
fit, or "snap" together so that the top of the electronics unit
132, the top of the motor 56 module and remaining elements of the
"floor" 148 of the dispensing unit 20 form a smooth, cleanable
surface. Paper dust and debris tend to accumulate on the floor 148
of the dispenser 20. It is important that the dispenser 20 is able
to be easily cleaned as part of the maintenance procedure. A quick
wiping with a damp cloth will sweep out and pick up any undesirable
accumulation. The removable modular dispensing shelf 64 may be
removed for rinsing or wiping.
The feed roller 50 may be driven by a motor 56 which in turn may be
driven by a battery or batteries 58, driven off a 100 or 220V AC
hookup, or driven off 20 a transformer which is run off an AC
circuit. The batteries may be non-rechargeable or rechargeable.
Rechargeable batteries may include, but not be limited to, lithium
ion, metal hydride, metal-air, nonmetal-air. The rechargeable
batteries may be recharged by, but not limited to, AC
electromagnetic induction or light energy using photocells.
A feed roller 50 serves to feed the paper towel being dispensed
onto the curved dispensing ribs 52. A gear train (not visible) may
be placed under housing 86, (FIG. 3) for driving the feed roller. A
control unit 54 (FIG. 3) for a motor 56 (FIG. 3) may be utilized. A
proximity sensor (not shown) or a hand-operated switch 64 may serve
to turn the motor 56 on and off.
As an enhancement and further development of a system for
delivering paper towel to the end user in as cost effective manner
and user-friendly manner as possible. An automatic means for
dispensing the paper towel is desirable, making it unnecessary for
a user to physically touch a knob or a lever. Therefore, a more
hygienic dispenser is present. This dispenser will contribute to
less transfer of matter, whether dirt or bacteria, from one user to
the next. The results of washing ones hands will tend to be
preserved and hygiene increased.
An electronic proximity sensor is included as part of the paper
towel dispenser. A person can approach the paper towel dispenser,
extend his or her hand, and have the proximity sensor detect the
presence of the hand. Upon detection of the hand, a motor is
energized which dispenses the paper towel. It has long been known
that the insertion of an object with a dielectric constant into a
volume with an electromagnetic field will tend to modify the
properties, which the electromagnetic field sees. The property of
the hand, a dielectric constant close to that of water, is enough
to alter the net capacitance of a suitable detector circuit.
An embodiment of the invention comprises a balanced bridge circuit.
See FIG. 8A. The component U1A 90 is a comparator (TLC3702 158)
configured as an oscillator. The frequency of oscillation of this
component, U1A 90, of the circuit may be considered arbitrary and
non-critical, as far as the operation of the circuit is concerned.
The period of the oscillator is set by the elements Cref 92, Rhys
94, the trim resistance, Rtrim 96, where the trim resistance may be
varied and the range resistors Rrange 152 are fixed. The resistors
Rrange 152 allow limits to be placed on the range of adjustment,
resulting in an easier adjustment. The adjustment band is narrowed,
since only part of the total resistance there can be varied.
Consequently a single potentiometer may be used, simplifying the
adjustment of Rtrim 96. A value for Rrange 152 for the schematic
shown in FIG. 8A might be 100 k.OMEGA.. Rtrim 96 might have an
adjustment range of 10 k.OMEGA. to 50 k.OMEGA.. The output signal
at pin 198 of component U1A 90 is a square wave, as shown in FIG.
9A. Cref 92 is charged by the output along with ANT 100, both
sustaining the oscillation and measuring the capacitance of the
adjacent free space. The signals resulting from the charging action
are applied to a second comparator, U1B 102, at pins 5104 and 6106
(FIG. 8A). These signals appear as exponential waveforms, as shown
in FIG. 9B and FIG. 9C.
The simplest form of a comparator is a high-gain differential
amplifier, made either with transistors or with an op-amp. The
op-amp goes into positive or negative saturation according to the
difference of the input voltages because the voltage gain is
typically larger than 100,000, the inputs will have to be equal to
within a fraction of a millivolt in order for the output not to be
completely saturated. Although an ordinary op-amp can be used as
comparator, there are special integrated circuits intended for this
use. These include the LM 306, LM311, LM393 154 (FIG. 8A), LM393V,
NE627 and TLC3702 158. The LM393V is a lower voltage derivative of
the LM393 154. The LM393 154 is an integrated circuit containing
two comparators. The TLC3702 158 is a micropower dual comparitor
with CMOS push-pull 156 outputs. FIG. 8B (prior art) is a schematic
which shows the different output structures for the LM393 and the
TLC3702. The dedicated comparators are much faster than the
ordinary op-amps.
The output signal at pin 198 of component U1A 90, e.g., a TL3702
158, is a square wave, as shown in FIG. 2A. Two waveforms are
generated at the inputs of the second comparator, U2B 102. The
first comparator 90 is running as an oscillator producing a
square-wave clocking signal, which is input, to the clock input of
the flip-flop U2A 108, which may be, for example, a Motorola D
flip-flop, No. 14013.
Running the first comparator as a Schmitt trigger oscillator, the
first comparator U1A 90 is setup to have positive feedback to the
non-inverting input, terminal 3110. The positive feedback insures a
rapid output transition, regardless of the speed of the input
waveform. Rhys 94 is chosen to produce the required hysteresis,
together with the bias resistors Rbias1112 and Rbias2114. When
these two bias resistors, Rbias1112, Rbias2114 and the hysteresis
resistor, Rhys 94, are equal, the resulting threshold levels are
1/3 V+ and 2/3 V+, where V+ 158 is the supply voltage. The actual
values are not especially critical, except that the three resistors
Rbias1112, Rbias2114 and Rhys 94, should be equal, for proper
balance.
The value of 294 k.OMEGA. maybe used for these three resistors, in
the schematic shown in FIG. 8A.
An external pullup resistor, Rpullup1116, which may have a value,
for example, of 470.OMEGA., is only necessary if an open collector,
comparator such as an LM393 154 is used. That comparator 154 acts
as an open-collector output with a ground-coupled emitter. For low
power consumption, better performance is achieved with a CMOS
comparator, e.g., TLC3702, which utilizes a cmos push-pull output
156. The signal at terminal 3110 of U1A charges a capacitor Cref 92
and also charges an ANT sensor 100 with a capacitance which Cref 92
is designed to approximate. A value for Cref for the schematic of
FIG. 8A, for the most current board design, upon which it depends,
is about 10 pF. As the clocking square wave is effectively
integrated by Cref 92 and the capacitance of ANT 100, two
exponential signals appear at terminals 5104 and 6106 of the second
comparator U1B, through the Rprotect 160 static protection
resistors. Rprotect 160 resistors provide limiting resistance which
enhances the inherent static protection of a comparitor input
lines, particularly for the case of pin 5104 of U1B 102. In the
schematic shown in FIG. 8A, a typical value for Rprotect 160 might
be 2 k.OMEGA.. One of the two exponential waveforms will be
greater, depending upon the settings of the adjustable resistance
Rtrim 96, Cref 92, and ANT 100. The comparator U1B 102 resolves
small differences, reporting logic levels at its output, pin 7118.
As the waveforms may initially be set up, based on a capacitance at
ANT 100 of a given amount. However, upon the intrusion of a hand,
for example, into the detection field of the antenna ANT 100, the
capacitance of ANT 100 is increased significantly and the prior
relationship of the waveforms, which were set with ANT 100 with a
lower capacitance, are switched over. Therefore, the logic level
output at pin 7118 is changed and the d flip-flop 108 state is
changed via the input on pin 5 of the D flip-flop 108.
The second comparator 102 provides a digital quality signal to the
D flip-flop 108. The D flip-flop, U2A 108, latches and holds the
output of the comparator U1B 90. In this manner, the second
comparator is really doing analog-to-digital conversion. A suitable
D flip-flop is a Motorola 14013.
The presence, and then the absence, of a hand can be used to start
a motorized mechanism on a paper towel dispenser, for example. An
embodiment of the proximity detector uses a single wire or a
combination of wire and copper foil tape that is shaped to form a
detection field. This system is very tolerant of non-conductive
items, such as paper towels, placed in the field. A hand is
conductive and attached to a much larger conductor to free space.
Bringing a hand near the antenna serves to increase the antenna's
apparent capacitance to free space, forcing detection.
The shape and placement of the proximity detector's antenna (FIG.
8A, 100) turns out to be of some importance in making the proximity
sensor work correctly. Experimentation showed that a suitable
location was toward the lower front of the dispenser unit. The
antenna (FIG. 8A, 100) was run about two-thirds the length of the
dispensing unit, in a modular, replaceable unit above the removable
dispensing shelf 62 (FIG. 3). This modular unit would be denoted on
FIG. 3 as 120.
A detection by the proximity detection circuit (FIG. 8A) in the
module 120 sets up a motor control flip flop so that the removal of
the hand will trigger the start of the motor cycle. The end of the
cycle is detected by means of a limit switch which, when closed,
causes a reset of the flip-flop and stops the motor. A cycle may
also be initiated by closing a manual switch.
A wide range of sensitivity can be obtained by varying the geometry
of the antenna and coordinating the reference capacitor. Small
antennae have short ranges suitable for non-contact pushbuttons. A
large antenna could be disposed as a doorway-sized people detector.
Another factor in sensitivity is the element applied as Rtrim. If
Rtrim 96 is replaced by an adjustable inductor, the exponential
signals become resonant signals with phase characteristics very
strongly influenced by capacitive changes. Accordingly, trimming
with inductors may be used to increase range and sensitivity.
Finally, circuitry may be added to the antenna 100 to improve range
and directionality. As a class, these circuits are termed "guards"
or "guarding electrodes," old in the art, a type of shield driven
at equal potential to the antenna. Equal potential insures no
charge exchange, effectively blinding the guarded area of the
antenna rendering it directional.
The antenna design and trimming arrangement for the paper towel
dispenser application is chosen for adequate range and minimum
cost. The advantages of using a guarded antenna and an adjustable
inductor are that the sensing unit to be made smaller.
From a safety standpoint, the circuit is designed so that a
detection will hold the motor control flip-flop in reset, thereby
stopping the mechanism. The cycle can then begin again after
detection ends.
The dispenser has additional switches on the control module 54.
FIG. 3 shows a "length-of-towel-to-dispense-at-one-time"("length")
switch 134. This switch 134, is important in controlling how long a
length of paper towel is dispensed, for each dispensation of towel.
It is an important setting for the owner of the dispenser on a
day-to-day basis in determining cost (to the owner) versus the
comfort (to the user) of getting a large piece of paper towel at
one time.
A somewhat similar second switch 136 is
"time-delay-before-can-activate-the-dispensing-of
another-paper-towel"("time-delay") switch 136. The longer the time
delay is set, the less likely a user will wait for many multiple
towels to dispense. This tends to save costs to the owner.
Shortening the delay tends to be more comfortable to a user.
A third switch 138 is the sensitivity setting for the detection
circuit. This sensitivity setting varies the resistance of Rtrim 96
(FIG. 8A). Once an effective antenna 100 (FIG. 8A) configuration is
set up, the distance from the dispenser may be varied. Typical
actual use may require a sensitivity out to one or two inches,
rather than four or six inches. This is to avoid unwanted
dispensing of paper towel. In a hospital setting, or physicians
office, the sensitivity setting might be made fairly low so as to
avoid unwanted paper towel dispensing. At a particular work
location, on the other hand, the sensitivity might be set fairly
high, so that paper towel will be dispensed very easily.
While it is well known in the art how to make these switches
according to the desired functionalities, this switch triad may
increase the usefulness of the embodiment of this invention. The
system, as shown in the embodiment herein, has properties of
lowering costs, improving hygiene, improving ease of operation and
ease of maintenance. This embodiment of the invention is designed
to consume low power, compatible with a battery or battery pack
operation. In this embodiment, a 6 volt DC supply is utilized. A
battery eliminator may be use for continuous operation in a fixed
location. There is a passive battery supply monitor that will turn
on an LED indicator if the input voltage falls below a specified
voltage.
Although the present invention and its advantages have been
described in detail, it should be understood that various changes,
substitutions and alterations can be made herein without departing
from the spirit and scope of the invention as defined by the
appended claims. Moreover, the scope of the present application is
not intended to be limited to the particular embodiments of the
process, machine, manufacture, composition of matter, means,
methods and steps described in the specification. As one of
ordinary skill in the art will readily appreciate from the
disclosure of the present invention, processes, machines,
manufacture, compositions of matter, means, methods, or steps,
presently existing or later to be developed that perform
substantially the same function or achieve substantially the same
result as the corresponding embodiments described herein may be
utilized according to the present invention. Accordingly, the
appended claims are intended to include within their scope such
processes, machines, manufacture, compositions of matter, means,
methods, or steps.
* * * * *